Complete prefabricated mechanical &amp; utility system

ABSTRACT

A complete prefabricated mechanical and utility unit for residential or commercial use that includes all utilities and mechanics for servicing the adjacent uses. Once attached to utility supply lines the invention does not require work from skilled labor to operate. The unit has the ability to support satellite services as required.

FIELD OF INVENTION

The present invention relates to a prefabricated system incorporating acomplete mechanical and utility unit that can operate as a stand alone“closed system” with the possibility of elements being added on at thetime of construction or at a later date.

BACKGROUND

Traditional construction practices for constructing a building are notefficient and wasteful of time of skilled labor, materials and futureresources to operate. One of the major expenditures of the overall costof any project is skilled labor (e.g. Electricians, Plumbers, etc.). Theskilled labor is also required to work at the job site which is notefficient in many ways. Two examples of this are: the skilled labor isrequired to travel to and from the site and the skilled labor mustrelocate all of their equipment throughout the project as the work iscompleted.

The common solution to this problem has been to prefabricate Modularbuildings in part or whole. Current prefabrication techniques can beclassified in those two groups but both have drawbacks. Whole fabricatedbuildings are difficult to transport to the site and erect. Partiallyfabricated units are not complete and must be assembled often resultingin double the amount of structure (walls, slabs, etc.). Attaching saidunits also require a great amount of on site skilled labor to assemblethe mechanical systems. The resultant joints between the units leave apotential for failure. These prefabricated buildings or modules providelimited design flexibility, allowing few configurations and notrecognizing specific site or design conditions.

In current building techniques incorporation of the mechanical systemsinto the building can require unnecessary time, for example theelectrician may be required to come to the site before the foundationpour to place electrical conduit. by limiting the required integrationof the mechanical system into the other building materials it wouldgreatly increase efficiency and reduce costs.

Often storage space is limited and difficult to secure on a constructionsite. Prefabrication offers a solution by not requiring raw materials tobe stored on site waiting to be installed.

The idea of a grouping plumbing and mechanical walls creating a servicecore is not a novel idea, but rather it is a fundamental principle inthe vertical organization of architecture. One solution proposed by pastinventions have created prefabricated systems that can be stacked orassembled to create this service core, but the connections andstructural intersections make these systems difficult to use in thefield requiring special knowledge for installation and construction.These connections are also a possible point of failure in the systems.

Therefore devising building techniques that reduce skilled labor andincrease efficiency are desired.

SUMMARY OF THE INVENTION

I have discovered a novel construction system that would be a completeprefabricated mechanical and utility unit, herein referred to as “theunit”. The system would include all mechanical and utility systems forthe building to operate. The Unit utilizes the most efficient method ofbuilding (prefabrication) for the most expensive part of construction(Mechanical & Utility Systems).

The system is comprised of multiple walls and floor diaphragms thatprovides structure while housing the mechanical & utility systems.

These units could be assembled on an assembly line similar to techniquesused to manufacture automobiles.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the complete prefabricated mechanical &utility system

FIG. 2 is a axonometric view of the unit, installed as possible use

FIG. 3 is a perspective view of the unit, installed as possible use

FIG. 4 is a perspective view of the unit, installed as possible use

FIG. 5 is a perspective view of the unit, looking up a ceiling cavity

FIG. 6 is a perspective view of the unit, installed as possible use

FIG. 7 is a perspective view of the unit, installed as possible use

FIG. 8 is a perspective view of the unit, installed as possible use

FIG. 9 is a perspective view of the embedded mechanical systems

FIG. 10 is a axonometric view of the foundation

FIG. 11 is a diagram of the possible delivery system

FIG. 12 is a longitudinal elevation of the unit

FIG. 13 is a section through the unit

FIG. 14 is the exterior elevation

FIG. 15 is the interior elevation

FIG. 16 is a plan view of the roof top

FIG. 17 is a plan view of the Foundation

FIG. 18 is a plan view of the unit

FIG. 19 is an example first floor plan using the unit

FIG. 20 is an example second floor plan using the unit

FIG. 21 is a plan view of an example hotel use

FIG. 22 is a plan view of possible configuration

FIG. 23 is a plan view of possible configuration

FIG. 24 is a plan view of possible configuration

FIG. 25 is a plan view of possible configuration

FIG. 26 is a plan view of possible configuration

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the invention can be used in the construction ofbuildings to reduce cost, improve efficiency, reduce construction time,and decrease a buildings operational costs. The unit is prefabricated ata factory and is of a transportable size. The unit is transported to asite that is prepared for the installation of the unit. The unit wouldpreferably be fabricated in an assembly line method.

The prepared site would preferably have foundation and all utilityinlets in place. A premade form is used to cast the foundation and withensure proper placement of utility inlets while reducing the cost andwaste of additional formwork when pouring the foundation.

The invention is a part or whole of the mechanical and utility systemsfor a building. Once installed and inlets have been attached the systemis able to operate. Additional elements may be added at the site so thatthe unit can be customized to any situation. The ability to becustomized makes the system extremely flexible and able to adapt to anysituation, increasing its design flexibility.

The unit is built of traditional building materials so that no specialknowledge is required to install, modify, or repair. Wood framing isshown in FIG. 1 but other materials may be used to satisfy structural orother limitations.

An advantage of prefabricating the mechanical system is that it can beinspected prior to installation. Problems can be addressed prior to theunits being installed saving delays at the site. The units can also betested in the factory prior to shipment ensuring high standard ofquality. The automation system is pre-programmed at the factory reducingthe site work of the automation technician.

The units contain all the meters to monitor and control all theservices. External digital readouts can be placed anywhere on theexterior of the building as required by the utility services. The unitotherwise would be able to connect to the utility companies to reportusages though wireless or data lines. Two way communication would bepossible allowing the utility to communicate and control parts of thesystem as known in the art.

STRUCTURE—The vertical structural members (1) shows the frame of theunit to be of typical construction materials. The rim joist (2) showsthe edge beam parallel to the long wall, thus creating a cavity betweenthe edge beam and the longitudinal wall. The edge beam is able tosupport adjacent floor members. The structural sheathing (3) will allowthe unit to remain rigid during transportation and may provide lateralresistance in the completed building. A pressure treated sill (4) orsimilar material that would allow the unit to be placed directly on theconcrete foundation. Anchoring hardware (5) such as hold-downs thatwould securely fasten the unit to the foundation.

WEATHERPROOFING—The roof top waterproofing pan (8) is a one piece linermade of a durable impervious material such as plastic that lines therooftop parapet area to waterproof it, and is connected to the scupper(9) that is incorporated into the Liner allowing water to exit therooftop mechanical area. An overflow scupper (10) located at a higherelevation allows water to escape if the main scupper becomes obstructed.All weatherproofing connectors and flashing may be also manufactured toensure quality of construction.

WATER—The water supply is connected at the water meter (15) which ismonitored by the automation system. All of the water supplied to theunit is filtered at the water treatment module (16). The potable wateris then either sent into the cold water supply line (14) or sent to thetankless water heater (19). The hot water line (13) is supplied by thetankless water heater (19). The hot and cold water lines service all thefixtures in the unit and have additional connections to service otherfixtures.

WASTE LINES—The washer drain (6) is installed at a location that isready for immediate use and is connected to grey waste line (11). Anoverflow pan (7) made out of metal or plastic prevents water leakageincase the washer fails and is connected to the grey waste line (11).The shower/tub drain (21) is placed in location for immediate use and isconnected to the grey water line (11). The Solid waste line (12) isinstalled in the unit that connects the Sewer lateral to the plumbingfixtures that can not produce grey water easily such as the toiletsdrain (22), kitchen sink (23), and dishwasher. The waste line vent (20)is connected to the grey waste line (11) and the solid waste line (12)to vent them through the parapet of the unit.

GAS LINES—All required inlets and outlets are installed for all gasappliances. The gas line (24) is connected at the Gas meter (25) whichis controlled through the automation system. The gas line connects theequipment on the roof top such as the water heater (19), heat pump (26),and generator (34). The gas line is also connected to the clothes dryer(50) and to the stove connector line (54).

HVAC—The airconditioner/heatpump (26) is controlled by the automationsystem. The intake/exhaust grill (28) is made to resemble a traditionalchimney cap. The thermostat (29) is controlled by the automation system.

ELECTRICAL—The electrical supply is connected at the electrical meter(30) which is controlled by the automation system. Conduit (33) connectsthe meter (30) to the Electrical panel (31). The use of conduit and theproperties of its material could reduce the amount of EMF (ElectricalMagnetic Fields) exposure to the user of the unit. The electrical panel(31) is connected to and controlled by the automation system (32). Thegenerator (34) provides backup power if electrical service isinterrupted. Lighting (35) is preinstalled in the unit. Electricalconduit (33) is located at the edge beam (2) that is connected to theelectrical panel (31). This allows additional electrical fixtures to beplaced outside the unit and the wires can be fed to the panel.

AUTOMATION SYSTEM—Automation Systems are known in the art but arecurrently expensive to install. The systems abilities are able to beexpanded upon by incorporating it into a prefabricated system. The Unitdoes not require the use of an automation system but by using anautomation system it eliminates the need for certain elements. Suchelements are light switches, rather than skilled labor required toinstall the lights outside the unit, the lighting fixtures just need tobe plugged into the automation system.

PRE-INSTALLED ELEMENTS—Elements are included in the system that allowfuture systems to be installed, but any of these additional items couldbe incorporated into the unit if desired. Such elements are a powerconverter (37) pre-installed so that photovoltaic panels can be mountedon the building and plugged into the unit. A solar water heater junctionbox (39) is also installed so that solar water heaters can be mounted onthe building and plugged into the unit. A grey water holding tank (17)would store grey water to be used at the site where potable water is notrequired. A hydronic pump (18) would provide required pressure totransport grey water from element (17) to outlet. An air handler (27)that can be placed at any location in the project works in conjunctionwith the compressor/heatpump (26) so all heating and coolingrequirements can be met. Added photovoltaic panels (36) can be connected“plugged in” to power converter (37). Solar water heaters (38) connectto solar water heater junction box (39).

VENTING—Venting for all the equipment is installed in the unitterminating at the vent cap (43). Using the said ventcap reduces theamount of roof penetrations of the adjacent building reducing the chanceof waterproofing failure, reducing the time of the roof installation andreduces the amount of trade coordination. The laundry dryer duct (40) isconnected to the vent cap (43) and is ready for connection to the dryer.The Laundry make up air (56) is provided so that make up air is notrequired by additional means required for gas appliances. The Laundrymake up air (56) may use means to reduces air humidity such aspressurization to increase the efficiency of said dryer. The bathroomduct and fan (41) is installed, connected to the vent cap (43) and readyfor use to meet required codes for ventelation of the said bathroom. Thehood duct (44) is installed and connected to the vent cap (43) and isoperable when connected to the Hood (45). The tankless water heater (19)is equipped a exhaust vent (46) and an intake air vent (47). Therefrigerator vent (48) is provided to either exhaust the heat generatedby the refrigerator coils or use the exhaust heat to assisting thetankless water heater (19) or the air conditioner/heatpump (26) and iscontrolled by the automation system. The rooftop mechanical area may beequipped with ventilation as required by specific mechanical units. Allor any of the ventilation ducts may be equipped with mechanical means ofimproving efficiency (i.e. fans)

SHOWER/TUB DRYER—The shower/tub dryer (50) is a element that providesforce air from the room that it is located or outside air that is usedto dry said area reducing humidity limiting the growth of mold andfungus. The shower/tub dryer is controlled by the automation system andmay turn on or off when required to reduce moisture levels as requiredand is connected to the vent cap (43) via shower/tub duct vent (49).

DETECTORS—Detectors and sensors are placed throughout the unit tomonitor for system or building failures. The gas detector (60) islocated near the appliances that use gas or along parts of the unit thatgas might accumulate. The water detector (57) are located along thefloor and in the under floor vault, installed to monitor if sink/tuboverflows, washer malfunctions or if a pipe in the walls rupture. Awater sensor is also located in the roof equipment area to warn if thescuppers are blocked and the roof pan is filling with water. Firedetectors are provide including a Co² (58) detector and smoke detector(59). Security detectors (61) are ready for installation at typicallocations i.e. (doors, windows). All detectors are controlled by theautomation system. The automation system has the ability to shut offservices (i.e. gas, water), turn on fans to vent (i.e. gas), to signalaudible, visual, mechanical alarms or notify third party services suchas the fire department, police department, a security company, etc.

ENERGY CONSERVATION—By combining all of the mechanical systems togetherit will be possible to greatly conserve energy by reclaiming “lost”energy by using heat transfer devices. In typical construction heatexpelled from mechanical devices (i.e. clothes dyer, oven, refrigerator,or heatpumps) is considered “lost”. In the unit the excess heat would becollected though heat transfer devices known in the art and used by theunit to preheat or precool water or air to conserve energy. A geothermaltank system (63) is also incorporated as the automation system will usethe ground temperature in combination with any of the other devices toconserve energy by cooling water, air, or mechanical coils to improvetheir efficiency. Exterior temperature coils are mounted on the exteriorof the unit which allows the automation system to use extreme exteriortemperature in hot or cold climates to assist in providing heating orcooling for any of the incorporated devices, increasing the efficiencyof the unit as a whole.

The lifespan of all mechanical equipment is limited and dated. Newtechnology will make old units obsolete. The ability to update abuildings entire mechanical system would allow the remaining building tobe reused and preserved. The unit could be installed in such a manorthat it is not an integral part of the structure allowing it to beremoved and replaced with a new unit. The old unit could then berecycled.

A common problem with new or alternative building techniques is that itis difficult to incorporate the mechanical systems, at least the tradesmay provide resistance by increasing fees due to unknowns and unfamiliarconditions. By self containing the mechanical and utility systems itallows the use of alternative building techniques and materials. (i.e.straw bale, adobe, foam block)

DETAILED DESCRIPTION OF THE DRAWINGS

FIG. 2, FIG. 3, FIG. 4, FIG. 6, FIG. 7, and FIG. 8 show the unitinstalled with other elements. Element (45) shows the location of a hoodfor a stove. Element (52) shows the hotwater line installed on siteconnecting the unit to the kitchen sink. Element (53) is the coldwaterline installed on site connecting the unit to the kitchen sink.Element (54) is the gas line installed onsite connecting the unit to thegas appliances. Element (55) is the Ventilation duct connecting Element(45) to the Unit

FIG. 5 is a perspective view looking at the ceiling cavity of the unit.Element (42) is a fan unit connected to element (41) to (43). Element(50) is a dryer for the shower/tub.

FIG. 10 is an axonometric view of the prepared foundation. Thefoundation can be used with slab or raised floor construction. Theformwork (51) can be reused or made in mass such as plastic formwork.This would allow proper installation of site connections, structural andutility by precut holes and markings as required. The formwork may beremoved to use again or left in place.

The obvious method of transportation for multiple units would be on aflatbed truck and craned into place. This method is preferred ifmultiple units are to be installed but FIG. 11 is a diagram of apossible alternative delivery system that would allow for a single unitto be transported and erected without the use of a crane. The trailer(62) could be towed behind any vehicle and brought to the site. Saidtrailer would have the ability to tilt up the unit while aligning itwith the foundation using human or mechanical means.

VARIATIONS

Multiple variations are possible for the unit. Certain configurationsmay be more applicable than others depending on the intended use orspecific site/project conditions. The unit may be a single story ormultiple stories. The dimensions of the unit may very maintaining theunit is transportable. The unit could be constructed out of anyconstruction material. The unit can be double loaded (as shown) orsingle loaded (example: the plumbing wall is the exterior wall). Theunit may or may not structurally support the adjacent structure. Theservices can be located above, below or within the unit. The unit couldalso incorporate any mechanical or utility service, not only thespecific ones described in this document.

The unit may control any data, utility, or service. Items such as cable,Ethernet, dsl, phone, satellite, wireless data, detectors, monitoingequipment, etc. shall be apart of this document.

An example of a variation of the unit is one with no plumbing on theexterior wall and the mechanical equipment underneath the unit may bemore efficient in colder climates. The pipes could freeze in an exteriorwall and the other mechanical equipment would provide enough heat outputto keep the mechanical vault from freezing.

Another variation is a unit that allows other units or other systems tobe serviced by the Unit acting as a hub or core to the overall system.

The unit may also be used in the construction of milti-residential,hospitality and in healthcare projects due to the repetition ofmechanical and utility systems. For hospitality the front desk couldcontrol the rooms systems from the front desk. For the healthcareapplication the nurses station could monitor all of the incorporatedmedical equipment.

The unit may be used for emergency housing for organizations such asFEMA. A single story simplified version of the unit that does notincorporate such elements as the automation system. Appliances andfixtures would be installed and ready for use. The structure would bemade out of a material that could resist exposure to weather. Thesmaller size of this unit would allow for many more to be loaded on atransportation vehicle. This variation would allow for quick andefficient mechanical and utility support for emergency shelter. Afterthe emergency use is no longer required the same units could be madeavailable for reconstructing destroyed permanent housing.

1. A complete prefabricated mechanical and utility unit in the use ofbuilding construction comprising: (a) A structure with the ability tohouse and distribute all incorporated systems. (b) All building systemsthat will provide service the adjacent uses
 2. Said building systems (1a) shall include multiple or all but not limited to: electrical, gas,potable water, grey water, cold water, hotwater, solid waste, greywaste, hvac, lighting, data, phone, cable, dsl, satellite, solar water,photovoltaic, water purification, automation, ventilation, and metering3. The said unit is installed complete with the ability to provideoutside systems with services.